CT3701 - Instruction Manual For Gazcon PSA M2-V41 - 1

SC5062 Dalian CT3701
Instruction manual for Atlas Copco PSA Generator v. 1
(SW M2 v.40b)
[1]
Atlas Copco MCC, Marine Competence Center  www.Atlas Copco.com
Indhold
1. General Information ............................................................................................................. 3
1.1. Nitrogen Generator ........................................................................................ 3
1.2. Product warranty ........................................................................................... 3
2. Safety and Responsibility ...................................................................................................... 4
2.1. User’s Responsibility....................................................................................... 4
2.2. Safety devices ............................................................................................... 4
2.3. Dangers ........................................................................................................ 4
3. Nitrogen Generator Parts and Controls .................................................................................... 7
3.1. Basic Process Flow Description......................................................................... 7
3.1. Parts Description – Compressor and air dryer (Skid 1, 2) .................................... 9
3.2. Parts Description - Compressed Air Supply (Skid 3, 4 and 5) ............................... 9
3.3. Parts Description - Generator Section (Skid 6) ................................................. 10
3.4. Parts Description - Nitrogen buffer deck tank (Skid 20) .................................... 10
3.5. Parts Description - Outlet manifold and instrumentation (skid 8) ........................ 11
3.6. Controls ...................................................................................................... 12
3.7. Double Block & Bleed ................................................................................... 12
Block and bleed function SV14, SV15, SV16 ............................................................. 12
4. Receiving Inspection & Installation ....................................................................................... 13
4.1. Receiving Inspection .................................................................................... 13
4.2. Installation.................................................................................................. 13
4.3. Air Supply ................................................................................................... 13
4.4. Power Supply .............................................................................................. 13
5. Operation 14
5.1. Main screen................................................................................................. 14
5.2. Operation Screen ......................................................................................... 15
5.3. Parameter ................................................................................................... 18
5.4. Settings ...................................................................................................... 20
5.5. Alarm ......................................................................................................... 21
5.6. Alarm History .............................................................................................. 21
5.7. Log on ........................................................................................................ 22
6. Nitrogen, Production........................................................................................................... 22
6.1. Purging the system and producing nitrogen ..................................................... 22
6.2. Nitrogen, shut-down instruction ..................................................................... 22
7. Alarm set points and parameters ......................................................................................... 23
8. Troubleshooting ................................................................................................................. 23
8.1. Room - Alarms and Actions – if room surveillance is installed ............................ 23
8.2. Inlet air - Alarms and Actions ........................................................................ 23
8.3. Valves and regulating air – Alarms and actions ................................................ 23
8.4. Nitrogen - Alarms and Actions ....................................................................... 24
8.5. Instrumentation failure – Alarms and Action .................................................... 24
8.6. Date and Time ............................................................................................. 24
9. Maintenance 25
9.1. General ...................................................................................................... 25
9.2. Daily Monitoring........................................................................................... 25
9.3. Weekly Monitoring. ...................................................................................... 25
9.4. Yearly Monitoring. ........................................................................................ 25
10. Cause and effect table. ....................................................................................................... 27
11. Factory Settings................................................................................................................. 31
11.1. PSA Generator Alarm settings – factory settings ............................................ 31
11.2. Other settings – factory Settings .................................................................. 31
12. Status and running modes .................................................................................................. 32
[2]
1. General Information
1.1. Nitrogen Generator
This Atlas Copco Nitrogen generator is an on-site Nitrogen generating machine.
The generator takes the atmospheric air and separates the Nitrogen from the other gasses.
The process is completely regenerative which makes it reliable and virtually maintenance free.
1.2. Product warranty

The general terms and conditions follow the general conditions in ORGALIME S 2000 with the following
amendments:
1. Warranty period
The complete scope of supply is warranted for 13 months from ship deliverycommissioning.
The generator is warranted by Atlas Copco. All other equipment (compressor, dryer, etc.) is warranted by
the relevant manufacture.
2. General provision and limitations

2.1 Notwithstanding anything herein to the contrary, no warranty is made with respect to consumable parts
like filters, service kits, etc.
2.2 In order to be able to avail himself of the rights under this clause, the Purchaser shall inspect the
Product and notify Atlas Copco in writing of the inspection and possible defects in material or design without
delay and not later than 14 days from receipt of the product. The Purchaser shall ensure that Atlas Copco
shall have the opportunity to verify that the Product are duly covered by Atlas Copco’s warranty and to
inspect and remedy any alleged defects. Without notification the Product shall be constituted accepted by
the Purchaser.
3. Labour, transportation and inspection

All costs of transportation, freight, importation or insurance or local tax or customs clearances of product
or parts claimed not to be as warranted and of repaired or replacement parts shall be borne by the
Purchaser, whether relating to the return to or shipment from an authorized service facility of Atlas Copco.
Atlas Copco may require the return of any part claimed not to be as warranted to one of such facilities
designated by Atlas Copco, transportation prepaid by Purchaser, to establish a claim under this warranty.
4. After sales service

If necessary, hereby meaning that if the technical issue in question cannot be solved by instructions given
on phone, fax, or any other means of communication, a technician from Atlas Copco will attend to supervise
the repair/replacement of the spare part(s) in question.
5. Disclaimer
5.1 Under no circumstances or conditions, shall Atlas Copco’s liability, whether in respect of one claim or
in the aggregate, arising out of any contract exceed the purchase price payable under the contract to Atlas
Copco for the subject equipment or parts.
5.2 No statement, representation, agreement or understanding, oral or written, made by any agent,
distributor, representative, or employee of Atlas Copco which is not contained in the Warranty will be
binding upon Atlas Copco unless made in writing and executed by the Manager of Atlas Copco.
5.3 No claim will be considered, and the warranty will be considered null and void, if other than genuine
parts are used in the Product.
5.4 The obligation under this warranty is limited at Atlas Copco option, to:
- replace the part, free of charge or
- repair the part, free of charge or
- refund the part at Atlas Copco’s order price.
[3]
2. Safety and Responsibility

2.1. User’s Responsibility
Observe statutory and accepted regulations
Observe relevant statutory and accepted regulations during installation, operation and maintenance of
the equipment.
For example, nationally applied European directives and/or valid national legislation, safety and accident
prevention regulations or regulations related to pressure equipment installation and operation. If the
national regulations specify that registration and inspection of pressure equipment is required, it is the
customers’ obligation to do this. If periodic visual inspections are required, it is also the customers’
obligation to enter agreement with an approved inspection company. If establishment of a logbook is
required, it is also the customers’ obligation to do so.
Qualified personnel
Ensure that operating, installation and maintenance personnel are qualified and authorised to do their
tasks.
These are people who, by virtue of their training, knowledge and experience as well as their knowledge of
the prevailing conditions, can assess the work to be done and recognise the possible dangers involved.
Operating personnel
Authorised operating personnel:
• must be of legal age,
• must be conversant with and adhere to the safety instructions and sections of the user manual
relevant to operation of the equipment,
• must have received adequate training
Installation and maintenance personnel

Authorised installation and maintenance personnel:
• must be of legal age,
• must have read, be conversant with and adhere to the safety instructions and sections of the user
manual applicable to installation and maintenance,
• must be fully conversant with the safety concepts and regulations of electrical and compressed air
engineering.
• must be able to recognise the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
• must have received adequate training and authorisation for the safe installation and maintenance
on these equipments.
2.2. Safety devices

• Do not change, bypass or disable safety devices.
• Do not remove or obliterate labels and notices.
• Ensure that labels and notices are clearly legible.
2.3. Dangers
The general safety instructions in this chapter indicate the possible dangers and how to
deal with them. Working in hazardous zone demand for a very high level of safety awareness.
Failure to follow these rules may result in severe personal injury or property damage.
Awareness of danger sources

Here are to be found the various types of danger that can arise in connection with operation of the
equipment.
[4]
Electricity
• Allow only qualified electricians or trained personnel under the supervision of a qualified
electrician to work on electrical equipment according to electrical engineering regulations.
• Isolate all phases of the main power supply.
• Check that there is no voltage present.
• Switch off any external power sources.
• Use fuses corresponding with the equipment power.
• Regularly check that all electrical connections are tight.
• Follow the warnings and instructions on the labelling on each equipment or control box
• Seek detailed instruction in the specific manual for each sub-equipment.
• Whenever there is an indication or any suspicion that a machine part is not working properly
or becoming overheated, the system must be stopped, and there should not be any inspection
before the part is stopped completely.
• All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may never put out of action.
• Pressure, temperature, and gas gauges shall be checked regularly with regard to their accuracy.
They shall be calibrated or replaced whenever outside acceptable tolerances.
• If the safety labels are damaged or destroyed, they must be replaced to ensure operator safety.
• Keep the working area neat. Do not place pipes or cables in away that can increase the risk of
accidents.
• Always wear proper safety clothing when working with the system and always comply with
costumer regulations regarding working clothes.
Fire prevention
The following instructions must be followed to prevent any hazardous situations that can cause fire in the
working area. These rules should be followed together with the fire prevention rules that the costumer
might have.
 Smoking or any use of fire in the hazardous zones is strictly prohibited.
 Being in possession of any fire lighting equipment in the hazardous zones is prohibited.
 To reduce the risk of fire, the waste trays must be kept clean from oil.
 Never use mobile phones, non ATEX approved cameras and walk talkies, when not in safe area,
because these items can generate sparks.
 Sound the alarm immediately when a fire is discovered and notify the operating manager
afterwards.
Pressure force
Compressed gas is a contained force. Uncontrolled release of this energy can cause serious injury or death.
Before all work on a pressure system:

• close shut-off valves or otherwise isolate the equipment from the air network to ensure that no
compressed gas is released in an uncontrolled way,
• de-pressurize all pressurized components.
• If the internal pressure on the generator needs to be relieved, the Close-down procedure for the
generator must be followed, and it must be ensured that the button in the control panel is positioned
in “OFF”-position. Afterwards the ball valve on the outlet is closed and the piping on the outlet of
the generator is depressurised and disconnected. Then the pressure can be relieved on the ball
valve on the outlet.
• Do not carry out welding, heat treatment or mechanical modifications to pressure components (e.g.
pipes and vessels) as this influences the component’s pressure resistance. The safety of the
equipment is then no longer ensured.
Operating materials
• Strictly forbid fire, open flame and smoking.
• Use only manufacturer approved operating materials.
Unsuitable spare parts

Use only spare parts approved by the manufacturer for use in this equipment. Unsuitable
spare parts compromise the safety of the equipment.
Conversion or modification of the equipment
Do not permit modification of the equipment as this can compromise function and safe working.
[5]
Safe equipment operation

Here is found information to support safe conduct with the equipment.
Transport
• Use suitable lifting gear that conforms to local safety requirements.
• Make sure the centre of gravity is correctly positioned to avoid the machine tipping.
• Make sure the danger zone is clear.
Installation
• Make sure no power is applied when electrical connections are made.
• Only use electrical cables that are suitable and approved for the loads applied.
• Install or remove pressure lines only when they are in the depressurised condition.
• Only use pressure lines that are suitable and approved for the maximum working pressure and
medium used.
• Do not allow connecting pipes to be under mechanical stress.
• Do not step onto equipment components to climb up the equipment.
• On oxygen generators, it is recommended to install blow off piping to outside air from the relief
valves.
Location
• Install the equipment in a suitable room ref. Section 1.2
• Ensure adequate ventilation.
• Ensure accessibility so that all work on the equipment can be carried out without danger for
hindrance.
Operation
Carry out regular inspections:
• for damage,
• of the safety devices,
• of components needing to be monitored.
Maintenance / disconnect
• Make sure the equipment is disconnected from electrical power, is voltage-free and depressurised
before commencing any maintenance work. Follow the instruction on the control boxes “Do not
open the enclosure earlier than 15 min after switching off.”
• If the internal pressure on the generator needs to be relieved, the Close-down procedure for the
generator must be followed, and it must be ensured that the button in the control panel is positioned
in “OFF”-position. Afterwards the ball valve on the outlet is closed and the piping on the outlet of
the generator is depressurised and disconnected. Then the pressure can be relieved on the ball
valve on the outlet.
• When components are replaces, only identical components must be used.
Components removed from the equipment can still be dangerous:

Do not open or destroy removed components as some (inlet valves, for instance) are powerfully spring-
loaded.
Decommissioning / disposal
Dispose of the equipment in accordance with local environmental regulations.
[6]
3. Nitrogen Generator Parts and Controls

3.1. Basic Process Flow Description
The Atlas Copco Nitrogen Generator unit is designed for compressed air at 6 – 9 bar(g). The compressed
air supply shall be filtered through an air conditioning system consisting of refrigeration dryer, pre- and
micro filtration units and water drain.
All filtration units shall be equipped with automatic drain valves for removing water and oil. The air quality
must fulfil the quality defined in the section 4.3 Air supply.
Figure 1 on next page, shows an illustration on the principles in a PSA generator.
In the PSA Plant solution, identical PSA generator modules are built together and to regulate the air supply,
air tank is installed as buffer. Furthermore nitrogen buffer tank is installed.
The system is operated via a control system installed in a safe area or via the remote system in the deck
office.
[7]
Figure 1: General intro - How PSA works
[8]
3.1. Parts Description – Compressor and air dryer (Skid 1, 2)

References are made to the P&I Diagram and the Component list for the equipment:
Compressor CD01, CD02, CD03

Compresses feed air for the nitrogen production
Ball valves BA01.1, BA01.2, BA01.3

The compressors are connected to the piping with buterfly valves for closing off.
Air dryer AD01, AD02, AD03

Dries the feed air for the nitrogen generators.
3.2. Parts Description - Compressed Air Supply (Skid 3, 4 and 5)

References are made to the P&I Diagram and the Component list for the equipment:
Lubricator for control air: AL01

Adds a small amount of special pneumatic lubrication oil to the pilot air, to ensure the continued
operation of all pneumatically operated devices installed.
Butterfly valve BA03.1, BA03.2, BA03.3

The filtration Skid3 is assembled with butterfly valves for closing off.
Dew point sensor DP11

Measures the pressure dew point in the air supply line.
Pressure transmitter PT11

Transmits the measured pressure in the air supply line to the control system.
Temperature sensor and transmitter TT11

Transmits the measured temperature from the air supply line to the control system.
Air regulator: RV01

Butterfly valve with manual regulator. Feed air flow can be regulated via this valve.
Regulator for control air: RV02

Air pressure regulator equipped with a filter and a bowl for removing condensate. RV02 is regulating the
pilot air pressure for CV0X.1-0X.3 and CV06-10 (factory setting 6 bar).
Ballvalve BA04.1,
The pilot air is assembled with ballvalve for closing off
.
Ballvalve BA04.2,
The pilot air for oxygen analyser calibrating, is assembled with ballvalve for dry air to SKID 9.
Pre-filter SR01.X, SR02.X, SR03.X

Filtrates feed air for impurities from the air supply.
Drain from filter WD01.X, WD02.X

Automatic zero loss float drain devices. Will release any condensate accumulated.
[9]
3.3. Parts Description - Generator Section (Skid 6)

References are made to figure 1 and the P&I Diagram and the Component list for the equipment. “X”
indicates that there is more than one, identical component:
Ball Valve BA061.X, BA62.X

At the inlet and outlet of each generator module, a ball valve is installed to permit maintenance.
Ball Valve BA63.X

On the outlet a ball valve is installed to give access to local samples for local purity measures.
Flow Control FC01.X

A fixed flow control is installed to support the internal generator process.
Valves for delivery of Nitrogen NR01.X, NR02.X

The valves control the delivery of nitrogen to the nitrogen buffer tank from the PSA generator.
Pressure indicator PI01.X , PI02.X

The pressure indicators are installed on the generator cylinders, to make it possible to read the pressure
in the cylinders.
Pressure transmitter PT01.X, PT02.X

The pressure transmitters are installed on the generator cylinders, to make it possible to transmit the
pressure in the cylinders to the control system.
Safety valve SA01.X, SA02.X

The safety valves are installed on the generator cylinders, to avoid potential overpressure in the cylinders.
Valves for cycle operation SV01.X, SV02.X

The valves control the built-up of pressure in each the two cylinders in the PSA generator.
Valves for exhaust SV03.X, SV04.X

The valves control the exhaust from the two cylinders in the PSA generator.
Valves for equalizing SV05.X, SV06.X

The valves equalise the pressure between the two cylinders in the PSA generator.
Generator cylinder TK03,TK04,TK05,TK06,TK07,TK08,TK09,TK10,TK11,TK12.TK13 and TK14

The generator cylinders are filled with CMS. The cylinders are built together two and two in modules to
make a PSA system.
3.4. Parts Description - Nitrogen buffer deck tank (Skid 20)

References are made to figure 1 and the P&I Diagram and the Component list for the equipment:
Ball valve BA131, BA132, BA133 and BA134

The Nitrogen tank is connected to SKID 8 outlet manifold with ball valve for closing off.
[10]
Non return valve NR10

The nitrogen tank is connected to an open connection, non return to avoid outside gas7air to enter the
system.
Pressure indicator PI07

Indicates the pressure of the produced nitrogen.
Safety valve SA13

The safety valve prevents excessive pressure from building up should a malfunction occur.
Nitrogen buffer tanks TK20

Stores Nitrogen produced by the Nitrogen generators. The buffer tank provides stable flow and purity of
Nitrogen.
3.5. Parts Description - Outlet manifold and instrumentation (skid 8)

References are made to figure 1 and the P&I Diagram and the Component list for the equipment:
Butterfly valve BA81, BA82

The outlet manifold is fitted with ball valves for closing off, to permit maintenance.
Dew point sensor DP21

Measures the pressure dew point in the Nitrogen supply line.
Flow Control FC02

The Nitrogen supply flow control regulates the flow in the nitrogen supply, the flow regulator is controlled
by the control system and flow can be set between 500 and 3750 m3/hour according to demand.
O2-Analyzer GA01
Measures and analyzes the contents of O2 in the produced nitrogen.
Non return valve NR03, NR04

For shut off of the plant and to ensure that there will be no blowback of gas
in to the generator. NR04 can be manually shut with BA83.
Pressure transmitter PT21

Transmits the measured pressure in the nitrogen system to the control system.
Regulator for nitrogen pressure: RV03

Pressure valve with manual regulator. The pressure can be regulated via this valve.
Filter SR04
Filtrates any impurities in the nitrogen supply.
Purge system SV07-SV08

SV08 is a pneumatically operated shuttle valve placed in the nitrogen delivery. It works in connection
with SV07, also pneumatically operated shuttle valve, in a purge system, which will shut SV08 and purge
the nitrogen to exhaust if nitrogen is off specifications.
[11]
Deck tank SV13

SV13 is a pneumatically operated butterfly valve that open when system is running, and fill the decktank
with Nitrogen.
Dry air SV10 and RV04

Dry air can be activated via control panel, and activate the pneumatically operated bytterflyvalve SV10.
RV04 is a butterfly valve with manual regulator. Dry air flow can be regulated via this valve.
3.6. Controls
Please refer to the Local Control Panel in the section Operation, and the Electrical Manual.
3.7. Double Block & Bleed

Block and bleed function SV14, SV15, SV16
Pneumatic operated butterfly valves SV15 and SV16 open, and pneumatic operated axialvalve SV14 close
for bleed off when system is running.
Pressure transmitter PTFC02, PTFC03

Transmits the measured pressure in the nitrogen supply line to the control system.
Buterfly valve BA121

The Bouble block and blees is fitted with butterfly valves for closing off, to permit maintenance and safety.
Non returnvalve NR12

Prevent gas to go backwards the system.
P/V breaker PVC01

Will reliese any pressure or vaccum in the pipe line.
[12]
4. Receiving Inspection & Installation

4.1. Receiving Inspection
Upon receiving your Atlas Copco Nitrogen Generator, inspect the unit thoroughly for signs of damage. Any
signs of damage, either external or internal, should be noted on the delivery receipt, and also reported
immediately to both the Freight Company and Atlas Copco.
4.2. Installation
When installing a Atlas Copco generator the following must be done:
Remove the pallet and the transportation cover and place the installation as shown on the drawings supplied
by Atlas Copco.
4.3. Air Supply

The requirements to the supplied air are:
Pressure 6-8.6 bar (g)
Max. temperature of inlet air +45 degree C
Max. dew point of +3 degree C at 7.5 bar (g)
Filtration to max 0.01 micron dust
Oil residues through a coal filter and cartridge filter in series.
ISO 8573.2001.2.4.1 must be fulfilled
If the air supply requirements, according to specification are not met it might cause damage. It’s not
covered under the manufacturer's warranty.
The hose/piping used to bring air from the compressor to the Nitrogen generator should be designed to
handle a pressure of minimum 10 bar.
4.4. Power Supply

(Refer to Electrical Manual)
Proper voltage must be provided to the PSA plant at all times.
Improper voltage will cause damage and are not covered under the manufacturer's warranty.
Power should be supplied to the PSA plant from a grounded electrical outlet. It is recommended to use a
circuit that will not be accidentally turned off, as this will cause the unit to malfunction.
Power supply to the air compressors, please refer to the compressor manual.
[13]
5. Operation
5.1. Main screen
Main screen The main Screen is

showing the most
essential values in the
Nitrogen production. It
is used as startup
screen, and is
returnable from every
screen.
Previous screen
[14]
5.2. Operation Screen
Status mode
Control Field Flow Fields
Purity
sensor Parameter
Field
Log Fields
From the operation screen every mode and consumption of nitrogen can be chosen.
Parameter Field
Process value for air and nitrogen is showed in the bottom.
To operate the system the PSA plant have to be ready (Follow the startup procedure page 22). In the
parameter field there will be a status indication for the compressor and the dryers. All of them have to be
ready before the PSA plant can be started.
Flow Field
The Flow regulation is active in every running mode. The PSA plant is able to produce and deliver 750
Nm3/h. There are 3 options for production volume.
 Flow 1: ”Preset flow I” defined in the Process setting screen

 Flow 2: ”Preset flow II” defined in the Process setting screen
 Flow 3: Operator defined. Maximum rate 750 Nm3/h.
There is an indication beside the different flow options to illustrate which flow mode is active.
When a warning on N2 Dew point or O2-content appears, the flow regulation will be set to 300 Nm3/h and
the Nitrogen is let out through SV07 to open air. All “shutdown alarms” in all modes excl. “manual” will
close the Flow regulation.
Log fields
The HMI panel has a local log. A SD card is used for storage of data. Log fields are used to start and stop
the logging. The data are stored in two comma separated files, Data_log and Alarm_log. The data can be
transferred to a PC via the SD card. Press “Stop log” on operation screen before removing the SD card.
When data has been transferred to a PC, the SD card must be inserted to the local HMI panel again, before
starting the PSA system
Please note: No data will be logged without a SD card inserted or if the log is not started.
[15]
Status mode
There are several status modes (see the table of status mode page 29).
Purity Instrument
The purity Sensor fields are used for selection of the active Purity Sensor. Sensor 1 is GA01.
Control field
Manuel
The process is running the process-cycle without taking care of warnings or shutdowns. The process is
continued no matter what. The delivery on the outlet is only open when the N2 Dew-point and O2-content
are within limits.
Auto Purge
This is an automatic startup procedure for “auto”-mode. The production will start in manual mode and
automatically continue in “auto”-mode when PSA plant are running without any warning alarms.
If the system is running more than 30 minutes without deactivating the warning alarms, a failure screen
will appear. If any shut down alarms are active, Auto Purge cannot be selected.
Auto purging failed
There are one or more shutdown alarms active.

The system will not start producing.
The system is able to start in manual if the status
mode is not in Off line.
To start the system, look in the status mode window
and see description of status mode on page 29
Auto
Before choosing “Auto”-mode, all shutdown limits and Outlet O2 and Dew-point must be within limits (Status
mode have to be ”purging” see status mode table page 28).
The process cycle is controlled by the Nitrogen pressure. The system has a stop-pressure and a restart-
pressure (See table with other settings page 27). The stop-pressure and restart-pressure is a part of “auto”-
mode and is finishing and stopping the process cycle without giving a warning.
Auto Pressure
The outlet pressure is controlled by regulating the flow to have a predefined outlet pressure. If the outlet
pressure is too low, the flow regulating valve (FC02) opens until the predefined outlet pressure is reached.
If the outlet pressure is too high, the flow regulating valve reduces the flow until the predefined outlet
pressure is reached. If the predefined outlet pressure is not reached after 20 seconds the PSA plant stops.
The settings for Auto pressure can be changed in the settings menu (Password level two protected).
Dry Air
The function can only be activated when PSA plant is stopped. The supply air is used for drying cargo tanks.
No shutdowns are active in Dry Air mode. Dry Air can be stopped remote by pressing the remote stop
button. RV04 needs to be manually adjusted to the actual air flow. Closed the valve (RV04) until the air
pressure measured on PT11 is minimum 5 bar. The valve position depends on the number of compressors
running.
[16]
Stop
If PSA plant is running:
The system finalizes the process cycle and the system is stopped.
There is an indication on the side of the screen to illustrate which operation mode is active.
Compressors and air dryers must be stopped manually.
If Dry Air is running:
SV14 and SV10 closes. Compressors and air dryers must be stopped manually.
[17]
5.3. Parameter
Under Parameter there are 3 options.

 PSA Process value
 Air and N2 Process value
 Trending and historical logging
Parameter PSA
Illustrating and showing the pressure value in
the process cycle for all modules in the
generators.
 Module 1: TK03 & TK04
Showing Nitrogen outlet value
Modules can enabled/disabled by pressing the
square in upper left corner of each module.
Enabling/disabling are only possible when PSA
plant is stopped and service password entered.
Parameter Log
Trending and logging Selection. Automatically
saving to USB drive, if the log is started. The
trend screens is divided into following option:
 Air Inlet values
 Nitrogen Outlet values
 PSA Generator pressure
Parameter Air/N2
Parameter values for Inlet air and outlet
Nitrogen.
[18]
Parameters Log
All logging is saved to a USB drive when the system is running and the log is started. The parameters are
saved every 60 sec. The graphic parameters are showed in different colours, in the different trend view.
It is possible to scroll back and forward between the logging values and to zoom in and out.
The information is saved on the

USB drive in the back of the
screen every minute.
Please note: If the USB drive is
removed, the logging is no
longer active.
If data needs to be transferred

to a computer for analyzing, the
procedure for “Remove or
change USB drive” must be
followed.
[19]
5.4. Settings
Settings are password protected. In the menu “Settings”, parameters for warning and shutdown limits can
be changed. Under the Alarm list Page 28) there is a list for all warnings and shutdowns alarm, used in this
PSA plant. Factory settings (recommended values) are listed.
The login has an automatic logout functions after 5 minutes login.
Settings main screen

Touch the window for entering password and a
textbox will appear. After entering the
password push Enter, and alarm limit settings
will show.
Alarm limit settings

Touch the valuebox to change parameter for
Warning or shutdown alarm. The empty
valuebox is not used in this PSA Plant and
cannot be changed.
[20]
5.5. Alarm
The alarm screen shows all warning alarms, shutdown alarms and information alarm.
The alarms are showed in order, sorted by date and time. In the text field there will be a short description
of the alarm type.
The status field has the following values:
 N The alarm is activated

 NA The alarm is activated and
Acknowledged
 ND The Alarm has been
activated, but is now
deactivated
The alarm will automatically disappear

when the alarm isn’t activated and it
has been acknowledged.
Date format: MM/DD/YYY
5.6. Alarm History
The alarm history screen shows and

save all warning alarms, shutdown alarms
and information alarm.
The alarm is showed in order, after date

and time. In the text field there will
be a short description of the alarm type.
There can be scrolling between old

and new alarms in the right side of
the screen.
Every alarm in history is saved on the SD card in the back of the screen, if the log is started.
Please note: If the SD card is removed, the logging is no longer active.
Date format: MM/DD/YYYY
[21]
5.7. Log on
The log on function makes it possible to
enable and disable PSA modules in case
of maintenance. The PSA system must be
stopped before the PSA modules can be
enabled/disabled.
Username: service
Password: 1111
6. Nitrogen, Production
All Tag names/numbers are according to P&ID drawing
6.1. Purging the system and producing nitrogen

 Make sure that the following valves are fully open: RV01, BA01.1, BA01.2, BA01.3, BA03.1, BA03.2,
BA03.3, BA61.X, BA62.X, BA81, BA82, BA83, BA91, BA121.
 Make sure that the following valves are closed: BA63.X, RV04, BA92.
Step Description
1 Turn on the compressor and dryer (CD01, CD02, CD03, AD01, AD02, AD03)
2 Check that the status of compressors and dryers are all “ready”
Check that the pressure in the “Compressed Air Buffer” (TK01) reaches 6,5bar.
3 The pressure can be read on the pressure indicator: PI05 or in the control system.
Check that RV02 is adjusted to 6 bar.
Set the system in Auto purge and select the desired flow rate. The system will automatically
4 purge until O2 content and dew point are within specification and automatically switch to auto
operation.
5 Production will start as soon as nitrogen quality is within specification.
6 Flow rate can be changed during operation.
6.2. Nitrogen, shut-down instruction
Step Description
1 Activate the “Stop”-button in the “Operation”-screen and observe that the mode screen shows
“stopping”
2 Wait until all modules in the Generator have finished the programmed cycle and have stopped
and mode screen shows “ready for start”
3 Now the PSA plant is stopped.
4 Close BA91 to prevent loss in nitrogen pressure, due to the small amount of nitrogen used
for gas sampling in GA01
[22]
7. Alarm set points and parameters
Changing the basic set points and parameters requires authorised access.
An overview of all set points and parameters with factory default set points noted, and can be found on the
last page.
All parameters and set-points can be changed via the HMI’s.
User password is: 1111
8. Troubleshooting
8.1. Room - Alarms and Actions – if room surveillance is installed
Oxygen level low.

Open the door to the room and ventilate until level is within limits before entering.
Check the system for leaks on nitrogen pipes and storage vessels.
Oxygen level high

Open the door to the room and ventilate until level is within limits before entering.
Check the exhaust piping system for leaks.
8.2. Inlet air - Alarms and Actions
No inlet air pressure (PT11)

Check that feed air supply is working properly and no valves in the feed air supply are closed.
Inlet air pressure low (PT11)

Check air compressors for correct delivery pressure and capacity according to air supply requirements.
Inlet air temperature high/low (TT11)

Bring feed air temperature within specification. Check compressor and dryer coolers.
Feed air dew point high/low (DP11)

Feed air dew point must be within specification. Check air treatment units, compressor, cyclone filter, pre
and micro filter, air dryer and drains.
8.3. Valves and regulating air – Alarms and actions
Malfunctioning shuttle valves (SV).

Carry out maintenance of shuttle valve according to procedure in Binder II, section Valves for correct
maintenance procedure
[23]
8.4. Nitrogen - Alarms and Actions
Nitrogen dew point high/low (DP21)

Verify correct feed air dew point, if ok run the unit at 330m3/h for 30 minutes and verify that nitrogen dew
point is within specification.
The Dew point is high at start up. To minimize high dew point at start up, run the plant once every week
for one hour.
Nitrogen purity alarm

Decrease flow and observe that oxygen concentration comes within specification.
If a significant decrease in performance is present. Switch between the tree positions of the Gas sample:
Nitrogen outlet, Unit 1 and Unit 2. This will make it possible to decide which Unit is malfunctioning. Shut
off the malfunctioning unit by closing BA61.X and BA62.X depending on which unit is malfunctioning.
Low Nitrogen pressure (PT21)

Check inlet air supply and make sure all columns are running correctly.
Make sure flow rate is within limits.
8.5. Instrumentation failure – Alarms and Action

If the system does not get a signal from an instrument, an alarm will be issued. In general, the action
required is to check the status of the instrument. The instrument can be damaged or a cable can be cut.
The following alarm messages are issued:
PT11 - Alarm message: “Inlet pressure instrument (PT11)”

TT11 - Alarm message: “Inlet temperature instrument (TT11)”
DP11 - Alarm message: “Feed Air dew point instrument (DP11)”
PT21 - Alarm message: “Outlet Pressure Instrument (PT21)”
DP21 - Alarm message: “N2 dew point Instrument (DP21)”
GA01 - Alarm message: “O2 Content Instrument (GA01)“
8.6. Date and Time

If the date or time is not correct, it can be correct by activating “Control Panel” during start up of the HMI
panel in the control box.
Unplug the electrical connector from the HMI Panel inside the control box, wait a few seconds, and plug it
in again. During start up a “Control Panel” option is shown. It is recommended to use GMT.
This can be done while the PSA plant is running.
[24]
9. Maintenance
9.1. General
For maintenance and trouble shooting of the auxiliary equipment e.g. Filters, Switchboard, Valves etc. pls.
refer to the manuals for the respective equipment in binder 2.
WARNING: The interior of the electrical cabinet contains electrical parts that may produce electrical hazard
if not handled properly. To prevent electrical shock, care must be taken when servicing this equipment.
Monitoring the operation of the unit on a regular schedule is the best way to insure a long life for your Atlas
Copco Nitrogen Generator Plant. The generator's operation should be monitored both daily and monthly as
described in the following sections.
Please observe that the container must always be electrically connected due to the function of the heater
and internal gas alarms.
9.2. Daily Monitoring

The daily monitoring of the Nitrogen generator consists of simply observing for few minutes each day the
operation of the unit to make sure that the automatic drains are not releasing excessive amounts of water
CAUTION: Condensate is not supposed to build up in SR01, SR02 and TK01. If significant amounts of
condensate are released from water drains, the reason must be found and corrected. Water and oil
carryover from feed air will cause severe damage to the adsorbent, which is not covered under the
manufacturer’s warranty.
Check the level of AL01 refill with lubrication oil if necessary. (Special pneumatic lubrication oil FESTO
OFSW-32)
Check the pressure setting of RV02 and readjust if necessary (correct setting 5bar).
9.3. Weekly Monitoring.

Every week the plant is recommended to be pressurized and run for one hour. Start-up and shutdown must
be performed according to the procedure.
9.4. Yearly Monitoring.
Filters
With proper maintenance of the air compressor the expected life of the pre-filter elements in SR01 – SR02
and filter SR04 is 1 year or 3000hrs of operation, whichever comes first. Improper compressed air quality
could affect the operation of your Nitrogen generator. The filter elements supplied with each unit have been
factory selected based upon the units feed air requirements.
Filter inserts in RV02 for the control air and flow valve have to be changed Once a year.
[25]
Shuttle valve maintenance

Maintenance of shuttle valves (SV01.X to SV06.X) must be carried out once a year to ensure the correct
operation.
Refer to Binder II, section Valves for correct maintenance procedure
O2 sensor (GA01, GA02)

Please refer to the specific manual for the instrument. The manual can be found in binder II.
Sensor adjustment for O2 analyser
Close valve BA91 and open BA92, open valve BA04.2 at inlet manifold for Pilot air line 12. Check manual
for GA01, GA02 for adjustning. After adjusting close valve BA92, BA04.2 and open valve BA91.
CAUTION: The following will cause damage not covered under the manufacturer’s warranty:
Ambient air at a temperature above 45°C or below 5°C.
Water, oil, rust, scale and/or other foreign objects carryover in the feed air can damage filter elements
and/or plugged drains.
WARNING: Atlas Copco filter elements have been selected based upon their ability to function
in severe operating conditions. Use of other than original equipment manufacturer filters could
cause damage not covered under the Atlas Copco warranty.
Flow adjustment for O2 analyser

Turn the knob FCGA01 until correct flow of 0,5l/min to 2L/min is observed. The flow is pre-set by Atlas
Copco.
Set point for filter regulator SR06 is 1 bar.
[26]
Information
Running mode Discription
mode
The PSA line is not ready for any modes. Missing running signal from
x
compressor.
System is ready to start. There is a running signal from compressor
x
and both dryers.
Auto purging. The generator is starting in manual mode until it is free of
x any shutdowns and outlet warning (O2 and Dew point). Thereafter the
system automatically starts in “auto” mode.
The system is running in Manual. No shutdowns are active. Outlet O2
x
content and dew-point is controlling the purging valve for delivering
The system is running as in Auto mode. The outlet N2 flow is controlled by
X
outlet pressure.
The system is running as in Auto mode. The connection for deck tank is
X
open (RV13).
x The system is finishing the process cycle and stopping
X The Dry Air supply valve is open (SV10). No shutdowns are active.
Pressure limit is showed when process is waiting for the pressure to drop
(not in Manual).
In every run mode besides ”Manuel” mode, the process cycle is controlled
x
by a pressure stop and restart. If the Nitrogen outlet pressure is getting to
high the process cycle is finishing and stopping the process. The process
will resume when the pressure is falling under restart limit.
Shutdown error is showed when the process is having a shutdown alarm
(not in Manuel).
x
In every run mode beside ”Manuel” mode the process cycle will stop after
finishing the process cycle. The alarm will appear in the alarm window.
In ”auto” running mode, the system will purge, if the warning limits for
x
Nitrogen outlet (O2 content and dew-point) is activated.
10. Cause and effect table.
PSA alarms &

Alarm Shutdown Cause Effect Note
indication
Low feed air Local warning and

Air pressure
4.5 bar pressure common alarm
PT11
High feed air Local warning and

Air pressure
PT11
Shutdown of N2
High feed air
Air pressure 10.0 system and
pressure 1
PT11 bar common alarm
Low feed air Local warning and

Air temperature
5 °C temperature common alarm
TT11
High feed air Local warning and

Air temperature
45 °C temperature common alarm
TT11
Atlas Copco A/S  Oldvej 1A  DK-3540 Lynge  Tel. +45 44 99 69 00  info@Atlas Copco.com  www.Atlas
Copco.com
Shutdown of N2
High feed air
Air temperature system and
55 °C temperature 1
TT11 common alarm
Low feed air dew Local warning and

Air dew point
-1 °Ctd point common alarm
DP11
High feed air dew Local warning and

Air dew point
3 °Ctd point common alarm
DP11
Shutdown of N2
High feed air dew
Air dew point system and
5 °Ctd point 1
DP11 common alarm
Low internal N2 Local warning and

N2 Outlet
pressure PT21
High internal N2 Local warning and

N2 Outlet
pressure PT21
Shutdown of N2
High internal N2
N2 Outlet 9.5 system and
pressure 1
pressure PT21 bar common alarm
Local warning
Low N2 dew point
N2 dew point
N2 dew point (Indicates failure in
-90 °Ctd alarm and 2
DP21 measurement)
common alarm
Local warning,
N2 dew point
N2 dew point High N2 dew point
-40 °Ctd alarm and 2
DP21
common alarm
Shutdown of N2
system, N2 dew
N2 dew point High N2 dew point
-35 °Ctd point alarm and 1
DP21
common alarm
Low O2 content Local warning, O2
O2 content (Indicates failure in content alarm and
0% 2
GA01/02 measurement) common alarm
Atlas Copco A/S  Oldvej 1A  DK-3540 Lynge  Tel. +45 44 99 69 00  info@Atlas Copco.com  www.Atlas
Copco.com
PSA alarms &
Alarm Shutdown Cause Effect Note
indication
Local warning, O2
O2 content High O2 content content alarm and
5.5% 2
GA01/02 common alarm
Shutdown of N2
system, O2 content
O2 content High O2 content
6% alarm and common 1
GA01/02
Alarm
Missing feedback Instrument failure only
Flow instrument from sensor and (Local warning and
X
FC02 unrealistic value common alarm)
Pressure sensor Missing feedback Instrument failure only

on flow from sensor and (Local warning and
X
Instrument PT21 unrealistic value common alarm)
Pressure sensors
Missing feedback Instrument failure only
for pressure
from sensor and (Local warning and
vessels (PT01.#, X
unrealistic value common alarm)
PT02#)
N2 main line Missing feedback Instrument failure
pressure from sensor and (Local warning and
X
PTFC02 unrealistic value common alarm)
Value higher than
Shutdown of N2
N2 main line PT21, missing
system, local
pressure feedback from
X warning and 1
PTFC02 sensor and
common alarm
unrealistic value
N2 main line Trip signal for
N2 main line low
pressure 0.01 bar shutdown of cargo
pressure
PTFC02 pump.
N2 main line Missing feedback Instrument failure
pressure from sensor and (Local warning and
X
PTFC03 unrealistic value common alarm)
N2 main line pressure
N2 main line
0.05 bar high/low alarm. Local
pressure High/low pressure
0.2 bar warning and common
PTFC03
alarm
Pilot air pressure for
Monitoring of Low pilot air
DBB alarm, local
pilot air to DBB pressure in N2
4 bar warning and common
PS01 supply condition
alarm
Pilot air pressure for
Monitoring of Pilot air present in
DBB alarm, local
pilot air to DBB stop and shutdown
4 bar warning and common
PS01 conditions
alarm
Note: Comment
Shutdown of N2 system forces FC02, SV82. The valves are NC for “fail to safety”
1 operation. SV07 are forced open. The valves are NO for “fail to safety” operation.
Automatic purge is activated, SV08 is forced to close. SV07 is forced open.

2
[29]
Atlas Copco Marine Competence Center  www.Atlas Copco.com
Remote signals
Sensor Value Direct alarm Indirect alarm
Remote panel Common alarm

PT11

TT11

DP11
Remote panel/ High/low warning

PT21 analogue output Common alarm
DP21 Remote panel/ High/low warning Common alarm

analogue output
GA01 Remote panel/ High/low warning Common alarm

analogue output

FC02
PT21 (part of Common alarm

FC02)
PTFC02 Remote panel/ Common alarm

analogue output
PTFC03 Remote panel High/low warning Common alarm
PS01 X Common alarm
PTFC02/PTFC03 Trip signal for shutdown Common alarm

of cargo pumps
PT01.#, PT02.# Common alarm
[30]
11. Factory Settings
11.1. PSA Generator Alarm settings – factory settings
Low Shutdown Low Warning High Warning High Shutdown
Set point not relevant: The

Air Pressure (PT11) Bar (g) system will shut down 4,5 bar 9,5 bar 10,0 bar
because of high O2 Contents
Air Temperature (TT11) OC system will shut down 5 oC 45 oC 55 oC
Air Dewpoint (DP11) Ctd Not relevant -1 oCtd 3 oCtd 5 oCtd

N2 Pressure (PT21) Bar (g) system will shut down 4,0 bar 9.1 bar 9.5 bar
N2 Dewpoint (DP21) Ctd Not relevant -90 oCtd -40 oCtd -35 oCtd
O2 Content (GA01) % Not relevant 0% 5.5 % 6,0 %
N2 Pressure (PTFC02) Bar (g) 0.01 - - -
Pilot Air Pressure (PS01) Bar (g) 4 Bar - - -
11.2. Other settings – factory Settings
Process Cycle 47 sec

Equalization process 5 sec
Unit delay 9 sec
Delay time between process cycle & Equalization (cannot be changed) 1 sec
Auto Stop 8 bar
Auto Start 5 bar
N2 LOW-LOW pressure signal, delay 12 sec
[31]
12. Status and running modes
Information
Status mode Running mode Discription
mode
The PSA line is not ready for any modes. Missing running signal from compressor
Off line x
and dryers.
System is ready to start. There is a running signal from compressor
OK for start x
and both dryers.
Auto purging. The generator is starting in manual mode until it is free of any
Auto purge x shutdowns and outlet warning (O2 and Dew point). Thereafter the system
automatically starts in “auto” mode.
The system is running in Manual. No shutdowns are active. Outlet O2 content and
Manual x
dew-point is controlling the purging valve for delivering
Before choosing “Auto”-mode, all shutdown limits and Outlet O2 and Dew-point
Auto x
must be within limits. In “Auto”-mode all alarms and shutdowns are active.
The “Auto pressure”-mode is a function regulating the flow ensuring that the pressure
in the outlet is constant. The target value for the pressure is set in Administrator
settings “Process Settings”.
Auto pressure x
In the “Process Settings” fields for setting minimum and maximum values for the
pressure can be found. The delay in regulating the flow can be set as well as the
increments.
Stopping x The system is finishing the process cycle and stopping
Pressure limit is showed when process is waiting for the pressure to drop (not in
Manual).
In every run mode besides ”Manuel” mode, the process cycle is controlled by a
Pressure Limit x
pressure stop and restart. If the Nitrogen outlet pressure is getting to high the
process cycle is finishing and stopping the process. The process will resume when
the pressure is falling under restart limit.
Shutdown error is showed when the process is having a shutdown alarm (not in
Manuel).
Shutdown error x
In every run mode beside ”Manuel” mode the process cycle will stop after finishing
the process cycle. The alarm will appear in the alarm window.
In ”auto” running mode, the system will purge, if the warning limits for Nitrogen
Purging x
outlet (O2 content and dew-point) is activated.
[32]

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SC5062 Dalian CT3701

Instruction manual for Atlas Copco PSA Generator v. 1

1.2. Product warranty

2. General provision and limitations

3. Labour, transportation and inspection

4. After sales service

2. Safety and Responsibility

Installation and maintenance personnel

2.2. Safety devices

Awareness of danger sources

Before all work on a pressure system:

Unsuitable spare parts

Safe equipment operation

Components removed from the equipment can still be dangerous:

3. Nitrogen Generator Parts and Controls

Figure 1: General intro - How PSA works

3.1. Parts Description – Compressor and air dryer (Skid 1, 2)

Compressor CD01, CD02, CD03

Ball valves BA01.1, BA01.2, BA01.3

Air dryer AD01, AD02, AD03

3.2. Parts Description - Compressed Air Supply (Skid 3, 4 and 5)

Lubricator for control air: AL01

Butterfly valve BA03.1, BA03.2, BA03.3

Dew point sensor DP11

Pressure transmitter PT11

Temperature sensor and transmitter TT11

Air regulator: RV01

Regulator for control air: RV02

Pre-filter SR01.X, SR02.X, SR03.X

Drain from filter WD01.X, WD02.X

3.3. Parts Description - Generator Section (Skid 6)

Ball Valve BA061.X, BA62.X

Ball Valve BA63.X

Flow Control FC01.X

Valves for delivery of Nitrogen NR01.X, NR02.X

Pressure indicator PI01.X , PI02.X

Pressure transmitter PT01.X, PT02.X

Safety valve SA01.X, SA02.X

Valves for cycle operation SV01.X, SV02.X

Valves for exhaust SV03.X, SV04.X

Valves for equalizing SV05.X, SV06.X

Generator cylinder TK03,TK04,TK05,TK06,TK07,TK08,TK09,TK10,TK11,TK12.TK13 and TK14

3.4. Parts Description - Nitrogen buffer deck tank (Skid 20)

Ball valve BA131, BA132, BA133 and BA134

Non return valve NR10

Pressure indicator PI07

Safety valve SA13

Nitrogen buffer tanks TK20

3.5. Parts Description - Outlet manifold and instrumentation (skid 8)

Butterfly valve BA81, BA82

Dew point sensor DP21

Flow Control FC02

Non return valve NR03, NR04

Pressure transmitter PT21

Regulator for nitrogen pressure: RV03

Purge system SV07-SV08

Deck tank SV13

Dry air SV10 and RV04